BMW 328 328i 1999-2005 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: BMW Model: 3 Series Model Variant: 328i Codes Chassis Code: E46 Engine Code Primary: M52TUB28 👋 Introduction Market Position Segment: Compact Executive Sedan Bmw Positioning: Represents BMW's entry-level executive sedan offering, known for its engaging driving dynamics and premium build quality. Competitive Analysis Key Competitors: Mercedes-Benz C-Class (W203), Audi A4 (B6), Lexus IS (XE10), Infiniti G35 Key Features Driving Dynamics: Renowned for its balanced chassis, rear-wheel-drive platform, and communicative steering. Engine Performance: Smooth and torquey inline-six engine providing a refined power delivery. Build Quality: Typical BMW premium interior materials and solid construction. 📋 Manual Details Coverage Areas Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Specific Models Covered: BMW 328i Page Count Estimated Page Count: Approximately 1500-2500 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (likely PDF, often printable and searchable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, cooling system Engine Management: Fuel injection system (MS43/MS45 DME), ignition system, emissions control, sensor diagnostics, ECU testing Transmission Manual: Clutch, gearbox overhaul, shift mechanism, driveshafts Transmission Automatic: GM A5S360R/A5S390R transmission overhaul, valve body, torque converter, electronic control Drivetrain: Differential, rear axle, limited-slip differential (if equipped) Suspension: Front struts, rear multi-link suspension, control arms, bushings, springs, shock absorbers Brakes: Front and rear disc brakes (vented front), ABS system, DSC (Dynamic Stability Control), brake hydraulics, bleeding procedures Steering: Power steering system, steering rack, steering column, alignment specifications Electrical System: Battery, alternator, starter, lighting, fuses, relays, wiring diagrams, power distribution Body And Chassis: Body panels, doors, windows, sunroof, interior trim, bumpers, underbody protection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, climate control, refrigerant service Safety Systems: Airbag system (SRS), seat belt pre-tensioners, diagnostic codes Procedures Included Preventative Maintenance: Oil change intervals, fluid checks and replacements, filter replacement, spark plug replacement Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation Repair And Rebuild: Detailed step-by-step instructions for component removal, installation, and overhaul Diagnostics: Information on using diagnostic tools (e.g., INPA, DIS) and interpreting sensor data Electrical Repairs: Component testing, wiring harness repair, connector diagnosis Technical Depth Depth Of Coverage: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts Diagnostic Detail: Includes specific diagnostic trouble codes (DTCs), circuit descriptions, and component testing procedures Torque Specifications: Detailed torque values for all critical fasteners Alignment Specs: Front and rear wheel alignment specifications Schematics Included: Extensive electrical wiring diagrams for various systems 📊 Manual Specifications File Format File Format Type: Likely PDF (Portable Document Format) Searchability: Typically includes searchable text for quick information retrieval Printability: Designed for printing specific sections or the entire manual Print Quality Image Resolution: High-resolution for clear diagrams and illustrations Binding Type Binding: N/A (for digital format) Paper Type Paper Quality: N/A (for digital format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 6-cylinder, DOHC, 24 Valves Displacement: 2.8 Liters (2793 cc) Bore X Stroke: 84.0 mm x 84.0 mm Compression Ratio: 10.2:1 Performance Horsepower: 193 hp @ 5500 rpm Torque: 206 lb-ft (280 Nm) @ 3200 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (Bosch Motronic MS43 or MS45) Fuel Type: Premium Unleaded Gasoline (91+ octane recommended) Engine Features Valvetrain: Double VANOS (variable intake and exhaust camshaft timing) Engine Block Material: Aluminum Cylinder Head Material: Aluminum 🔧 Transmission Standard Standard Transmission: 5-Speed Manual (Getrag GS5-39DZ) Optional Optional Transmission: 5-Speed Steptronic Automatic (GM A5S360R/A5S390R) Features Transmission Cooling: External transmission fluid cooler for automatic transmission 📐 Dimensions Exterior Length: 177.4 inches (4506 mm) Width: 68.5 inches (1740 mm) Height: 55.7 inches (1415 mm) Wheelbase: 107.4 inches (2729 mm) Interior Front Headroom: 38.4 inches (975 mm) Front Legroom: 41.5 inches (1054 mm) Rear Headroom: 37.7 inches (958 mm) Rear Legroom: 33.4 inches (848 mm) Cargo Trunk Volume: 11.7 cu ft (331 L) Weights Curb Weight: Approximately 3350-3500 lbs (1520-1588 kg) Gross Vehicle Weight Rating: Approximately 4500 lbs (2041 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: 4 Stars (Driver), 4 Stars (Passenger) - 1999-2000 models, varies by year/testing protocol IIHS Side Impact: Good - Models with side airbags Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard ASC+T (Automatic Stability Control and Traction) Stability Control: Optional DSC (Dynamic Stability Control) on later models Passive Features Airbags: Frontal airbags, optional front side-impact airbags Seat Belts: Three-point inertia-reel seatbelts with pretensioners 💡 Technology Features Infotainment Head Unit: Factory Professional Radio/CD player, optional navigation system (MK III/MK IV). Display: Central LCD display for radio, climate, and navigation information. Driver Assistance Cruise Control: Standard electronic cruise control. Connectivity Bluetooth: Not available from factory; aftermarket solutions required. Features Headlights: Standard halogen headlights, optional Xenon HID headlights with adaptive beam. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 7,500 to 10,000 miles or annually, depending on...
Standard ASC+T (Automatic Stability Control and Traction)
Stability Control:
Optional DSC (Dynamic Stability Control) on later models
Passive Features
Airbags:
Frontal airbags, optional front side-impact airbags
Seat Belts:
Three-point inertia-reel seatbelts with pretensioners
💡 Technology Features
Infotainment
Head Unit:
Factory Professional Radio/CD player, optional navigation system (MK III/MK IV).
Display:
Central LCD display for radio, climate, and navigation information.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Bluetooth:
Not available from factory; aftermarket solutions required.
Features
Headlights:
Standard halogen headlights, optional Xenon HID headlights with adaptive beam.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles or annually, depending on driving conditions and oil used (BMW's Condition Based Service system is key)
Coolant Change:
Every 2-4 years or 30,000-60,000 miles
Spark Plug Replacement:
Approximately every 60,000 miles (check specific type, e.g., NGK BKR6EQUP)
Fluid Specifications
Engine Oil Type:
BMW Longlife-01 (LL-01) or LL-98 approved synthetic oil, SAE 5W-30 or 5W-40 recommended
Engine Oil Capacity:
6.5 U.S. quarts (6.2 Liters) with filter
Coolant Type:
BMW Blue Antifreeze/Coolant (G48 formulation) mixed 50/50 with distilled water
Transmission Fluid Manual:
BMW MTF LT-2 or equivalent (e.g., Red Line D4 ATF for some applications, check manual)
Transmission Fluid Automatic:
BMW ATF LT-3 or equivalent (e.g., Pentosin ATF1 or ZF LifeguardFluid 5)
Brake Fluid:
DOT 4 (BMW recommends DOT 4 HP or Super DOT 4)
Known Issues
Cooling System Failure:
Plastic expansion tank and coolant hoses prone to cracking; water pump failure is common.
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing gasket can leak.
Suspension Wear:
Control arm bushings, sway bar links, and rear shock mounts are common wear items.
Window Regulator Failure:
Plastic components in the window regulator mechanism are prone to breaking.
Ccv System:
Crankcase Ventilation (CCV) system can clog, leading to increased oil consumption and potential seal failure.
ABS Wheel Speed Sensors:
Front ABS wheel speed sensors are known to fail, triggering ABS and brake warning lights.
📚 Vehicle History
Brand Heritage
Bmw Philosophy:
BMW's reputation for engineering excellence, performance, and driver engagement originated in the early 20th century.
Model Evolution
E46 Generation:
The E46 generation (1998-2006) succeeded the E36 and is widely regarded as one of BMW's most successful and critically acclaimed generations of the 3 Series.
328I Placement:
The 328i occupied the upper-mid-range of the E46 sedan lineup, offering a potent blend of performance and luxury before the introduction of the 330i.
Production
Production Years E46:
1998-2006 (sedan and wagon), 1999-2006 (coupe and convertible)
Manufacturing Locations:
Primarily Dingolfing, Germany; also assembled in South Africa, Thailand, and Mexico
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
E46 3 Series models (including 323i, 328i, and later 330i) were frequently named to Car and Driver's 10Best list for their exceptional driving dynamics.
Ratings
Edmunds Review:
Edmunds consistently praised the E46 3 Series for its performance, handling, and luxury appointments.
Certifications
Euro Ncap:
E46 sedan achieved a 4-star Euro NCAP rating.
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